NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC. Design and Implementation of a Thermal Load Reduction System in a Hyundai Sonata PHEV Cory Kreutzer, Principal Investigator John Rugh, Task Leader National Renewable Energy Laboratory June 9, 2015 Project ID: VSS165 This presentation does not contain any proprietary, confidential, or otherwise restricted information. 2015 VTO Annual Merit Review and Peer Evaluation Meeting
Transcript
NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Design and Implementation of aThermal Load Reduction Systemin a Hyundai Sonata PHEV
Cory Kreutzer, Principal InvestigatorJohn Rugh, Task LeaderNational Renewable Energy LaboratoryJune 9, 2015
Project ID: VSS165
This presentation does not contain any proprietary, confidential, or otherwise restricted information.
2015 VTO Annual Merit Review and Peer Evaluation Meeting
• Risk Aversion: Manufacturers are reluctant to invest in and introduce new technologies
• Cost: Effective, timely evaluation of advanced vehicular components and configurations is needed.
• Range Anxiety: Large climate control loads can contribute significantly to electric drive vehicle (EDV) range anxiety
Fully Funded FOA Project• Total project funding: $3,054,817
o DOE share: $ 2,443,790o Contractor share*: $ 611,027
• Funding received in FY14: $ 2,443,790• Funding for FY15: $ 0
* Contractor share represents 20% cost share for the project
Timeline
Budget
Barriers
• Interactions/collaborations:o Hyundai America Technical Center, Inc.o Halla Visteon Climate Control Corp.o Sekisui Chemical Company, Ltd.o Pittsburgh Glass Works, LLC.o PPG Industries, Inc.o Gentherm Incorporatedo 3M Company
• Project lead: o National Renewable Energy Laboratory
Partners
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RelevanceTHE CHALLENGE
• Increased market penetration of EDVs requires overcomingo Original equipment manufacturer (OEM)
risk adversity in adopting new technologies
o Limited vehicle range and associated customer range anxiety
o Elevated cost of EDVs in comparison to existing conventional vehicles
• Climate control loads can significantly impact EDV range
• 2014 light-duty vehicle (LDV) fuel use estimated at approximately 3 billion barrels oil1
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1. Data Source: EIA Annual Outlook 2014 http://www.eia.gov/forecasts/aeo/data.cfm, accessed April 20152. Data Source: Argonne National Laboratory’s Advanced Powertrain Research Facility
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RelevanceTHE OPPORTUNITY Alignment with DOE VTP
• Reducing climate control loads can increase vehicle range too Enable battery sizing and cost reductionso Reduce climate control equipment sizingo Enable advanced heating, ventilation, and air
conditioning (HVAC) component technologies
• Load reduction system demonstration decreases OEM risk for adoption
• HVAC load reduction and advanced climate control design can positively impact occupant comfort
• Support vehicle systems key goals for 2011–2015 Program Plan:
By 2015, develop technologies and a set of options to enable up to 50% reduction in LDV petroleum-based consumption
• Support meeting EV Everywhere Grand Challenge targets
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Relevance
Increase grid-connected electric drive vehicle range by 20% during the operation of the climate control system over the standard vehicle configuration by reducing vehicle thermal loads• Design and implement the thermal load reduction system on a production
drivable vehicle• Test the range impact over the combined city/highway drive cycle at peak
heating and cooling conditions• Maintain occupant thermal comfort in implemented system
THE GOAL
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Milestones 2015
FY 2015 FY 2016 FY 2017
Tech. Development & Specification
Modeling and Analysis
Technology Evaluation Testing
Project Phase I
Project Phase II
Vehicle Integration
Operational Testing & Validation
M1
M3M2
M1: Receive award and hold kickoff meetingM2: Select vehicle platform for Phase I and II evaluationM3: Complete summer technology evaluation testing
April
1
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Approach – Two-Phase Process
Design and Development
Testing Analysis
Integration and Validation
Testing Analysis
Glazings
Paint
Zonal HVAC
Insulation
Seating
Individual Technologies
Down-Selected Technologies
Validated Models
Full SystemImpact on Range
National Results& Occupant Comfort
Individual Technology
Performance
TechnologyGo/No-Go
Phase I
Phase II
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Approach – Testing and Analysis StrategyTesting Analysis
Individual Technology HVAC Load
HVAC System Baseline Performance
National Level Range Estimation
HVAC Thermal System Modeling
Vehicle Cabin Thermal Load Modeling
Occupant Comfort Modeling
Validation Data
Validation Data
Validation Data
OEM Full System Vehicle Performance
Relevance Approach Accomplishments Collaborations Future Work
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Approach – Technology Areas
Solar Control GlassLight-weight GlassSolar Control FilmsHeated Windshield
Cabin Insulation
Individual Door Glass Defrost/Defogger
Solar Reflective Paint
Heated surfaces around driver
Ventilated/Cooled seats
Grid-connected preconditioning
Relevance Approach Accomplishments Collaborations Future Work
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Accomplishments – Business
• Completion of legal obligations between all parties involvedo Multiparty nondisclosure agreemento Intellectual property management plan
• Subcontracts for the following project partners (in progress as of April 1, 2015):o Hyundai America Technical Center, Inc.o Pittsburgh Glass Workso Halla Visteon Climate Controlo PPG Industrieso Sekisui
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Accomplishments – Vehicle Platform Selection
• The 2016 Hyundai Sonata plug-in hybrid electric vehicle (PHEV)* was chosen to be the vehicle platform for both Phase I and Phase II evaluation and modeling
• Prototype vehicles will be used for Phase I and production vehicles for Phase II * Photos above are of the 2015 Hyundai Sonata conventional vehicle
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Accomplishments – Phase I Preliminary Summer Test Plan
Configuration May June July August September
Baseline & North Facing
Insulation –Full & Partial
Precondition
Baseline – Max Loads
Glass Packages
Ventilated/ Cooled Seats
Solar Reflective Paint
CombinedTechnologies
Two-phase air conditioning test (pull-down & steady-state)
Vehicle Cabin Solar Thermal Soak Evaluation
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Accomplishments – Phase I Summer A/C Test Approach
• Split two-component A/C test approach: pull-down and steady-state• Energy use calculated as cumulative energy during each time interval• Decoupled pull-down and steady-state components expected to increase
repeatability and isolate technology impact on HVAC loads
A/C Pull-Down A/C “Steady-State” PhaseSoak
𝒕𝒕𝟎𝟎
𝒕𝒕𝟏𝟏,𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃𝒃 𝒕𝒕𝟐𝟐 𝒕𝒕𝟑𝟑
MAX A/C Auto A/C (closed-loop) Vehicle OFF
Aver
age
Inte
rior A
ir Te
mpe
ratu
re
time
Sunr
ise
𝒕𝒕𝟏𝟏,𝒎𝒎𝒎𝒎𝒎𝒎𝒃𝒃𝒎𝒎𝒃𝒃𝒃𝒃𝒎𝒎
Baseline ConfigurationModified Configuration
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Response to Previous Year Reviewer’s Comments
This is the first year of this project and therefore does not have previous year reviewer comments.
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Collaboration and Coordination
Hyundai America Technical Center• Subtier Industry Partner• Automotive OEM Supplier• Lead on Phase II Technology Integration• Lead on Phase II Full System Experimental Evaluation• Technology Supplier (Collaboration with Gentherm)
Halla Visteon Climate Control• Subtier Industry Partner• Baseline HVAC System Experimental Evaluation• HVAC System Modeling Support• HVAC System Control Support
Sekisui• Subtier Industry Partner• Advanced Glass Technology Material Supplier
3M• Subtier Industry Partner – In Kind• Advanced Solar Control Film Supplier• Advanced Insulation Technology Supplier
Gentherm• Subtier Industry Partner – In Kind• Door Defrost/Defog Technology Supplier• Heated Surfaces Technology Supplier (collaboration)• Advanced Seating Technology Supplier (collaboration)
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Proposed Future Work
Phase I: Technology Design and Development (FY15–16)• Complete summer and winter technology evaluation• Complete baseline HVAC system performance characterization for HVAC
model development • Continue human comfort, HVAC system, and vehicle modeling for
technology evaluation(s) and development of national level framework• Perform Phase I technology evaluation Go/No-Go for Phase II
Phase II: Technology Integration and Validation (FY16–17)• Integrate thermal load reduction technologies into drivable vehicle system• Perform operational cold weather, hot weather, and environmental chamber
testing at Hyundai America Technical Center facilities• Refine models with individual technology experimental results and perform
national level analysis• Final vehicle demonstration and project summary presentation to DOE
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Summary• The project’s focus is to implement a thermal load reduction
system into a GCEDV production vehicle in order to demonstrate the combined impact of previous and current work in this research area
• Key industry partners enable production-ready and cost-effective technologies and vehicle-level integration
• A combination of load reduction technologies and zonal climate control strategies are used to meet project goals
• Testing and modeling/analysis are used synergistically to quantify system performance and national relevance
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Summary
Accomplishments
• Initiated project with kickoff meeting and coordination on completion of multi-party NDA and IPMP documents
• Subcontract negotiations are in progress (as of April 1, 2015) for five subtier partners
• The 2016 Hyundai Sonata PHEV has been selected for the project vehicle platform
• Phase I summer test planning has been completed and A/C testing procedure identified
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Acknowledgements and ContactsSpecial thanks to:• David Anderson and Lee Slezak
Vehicle and Systems Simulation and Testing
For more information:Principal Investigator: Cory KreutzerNational Renewable Energy [email protected]
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Photo Credits
• Slide 4: Matt Jeffers, NREL• Slide 5: Matt Jeffers, NREL• Slide 11: Cory Kreutzer, NREL• Slide 19: Dennis Schroeder, NREL
